Circuit Board Scales, Krusius Brothers Blade

[dirtychrome]

What did you cut the PCB material with.

The Cutting part was easy.

Cutting, and rough shape was done with a dremmel cutting wheel. When I stripped the board to my desired area, I still left a lot of other components on it. This didn't leave a true flat surface to run on the band or scroll saw. unless I was to do it show side down, but I didn't want to ding up the solder tips.

There are already holes in the boards. After roughly sized, that allowed them to be bolted together, and shaped on the sander. Then sanded edges up to 2000.

The "hardest" parts were removing all the pieces, leaving a flat board. Then the sanding down solder tips without touching the green. Knowing that if it was touched, there is no touch up to that thin layer, required attention. Front side of scales are perfect from marring, with a uniform height to the solder tips. The back sides had the solder areas sanded flat to the green. I'll admit the back side does have some minor scratches.

Also contouring the edges after some epoxy was laid required attention, making sure only epoxy was removed and not touching the board.

[Rasoio]

Ok this is incredible!
I do have a question. I know the board is flat, I i read your comments about you having to sand down some of the solder points almost down to the green and I know you mentioned you used resin to coat them. But how did you get the resin to shape out so perfectly rounded like that?

[dirtychrome]

But how did you get the resin to shape out so perfectly rounded like that?

Lol-sand, sand, swear, recoat, sand recoat and repeat. Did I forget swear?

Sorry wasn't meant to be flippant. That was the twitter reply.

Coated the rear, flipped over layer a few more coats on show side. Sanded off rough edges and shape. Another layer up top(maybe more?) Shape again final coat, final sanding. Someplace in there, coated the rear again a few times sanding down again.

That's way abbreviated...each coat, waited 3-4 days, and sanded up to 2000 then back to 800 between each coat. Shaping generally done on the belt sander. Final sanding with MicroMesh to 12000. another Micromesh treatment after pinned (thanks for the recommendation in your posts Glen!)

I love to contour the edge of scales, leaving a round radius from top to bottom, and as thin as reasonable. The images I posted show a lot of glare, not only due to my crummy photography skills, but to demo the radius. It really is clear as glass.

A harder thing for me to complete until satisfaction was leaving a sharp 90 degree on the inner scales such as where wedge meets the scales.

[PaulCam]

Really cool and innovative.

[Bruno]

Very cool. I am impressed.
Novel idea and beautiful execution.